Skoda Octavia 1 service manual - Running Gear - 51035020

Service

Workshop Manual

Service Department. Technical InformationS00.5103.50.20 Edition 08.96

Running Gear

The Workshop Manual is intended only for use within the KODAOrganisation; it is not permitted to pass it on to third parties. 1996 KODA, automobilov a.s.

Service

List of Supplements to OCTAVIA Workshop Manual Edition: 06.05

Chassis

Replaces List of Supplements - Edition: 05.04

Supple-ment

Edition Subject Article Number

08.96 Basic Edition of Workshop Manual S00.5103.50.20

1 09.96 Supplement to Basic Edition S00.5103.51.20

2 03.97 Supplement to Repair Group 40 and 42; Repair Group

44, 45 and 48

S00.5103.52.20

3 11.97 Engine 1.9 l/81 kW TDI S00.5103.53.20

4 10.98 Engine 1.8 l/110 kW; Octavia Estate S00.5103.54.20

5 12.98 Drive shafts, vehicle measurement, Brake FN-3 S00.5103.55.20

6 06.99 Modifications to steering system, brakes, rear axle,

ABS; Engine 1.4 l/44 kW

S00.5103.56.20

7 11.99 4 wheel drive (4 x 4) S00.5103.57.20

8 04.00 Vehicles with ABS/EDS/ESP S00.5103.58.20

9 11.00 Anti-lock brake system MK60 S00.5103.59.20

10 02.01 Anti-lock brake system MK60 ESP S00.5103.60.20

11 05.01 Mechanical brake assistant, Brake FN-3 S00.5103.61.20

12 08.01 Text modifications to Repair Group 00, 40, 42 and 45 S00.5103.62.20

13 01.02 Text modifications to Repair Group 45 S00.5103.63.20

14 06.02 Text modifications to Repair Group 00, 40, 44, 45 and

46

S00.5103.64.20

15 11.02 Engine 1.9 l/96 kW PD, Supplement to Repair Group

00, 40, 42 and 45

S00.5103.65.20

16 04.03 Text modifications to Repair Group 40, 45 and 46 S00.5103.66.20

17 05.04 Text modifications to Repair Group 00, 40 and 44 S00.5103.67.20

18 06.05 Text modifications to Repair Group 00, 40, 42 and 45 S00.5103.68.20

19

20

Contents next page.

The Service Manual is intended only for use within the koda Organisation; it is not permitted to pass it on to third persons.

2005 KODA AUTO a. s.

Printed in CR

S00.5103.68.20

Edition 06.05S00.5103.68.20

------------ I ------------

OCTAVIA ServiceTable of Contents

00 Technical Data Page

Technical Data ............................................................................................................................. 00-1- The chassis .............................................................................................................................. 00-1- The steering system ................................................................................................................. 00-5- The brake system .................................................................................................................... 00-6- Wheels, tyres ........................................................................................................................... 00-8

40 Front wheel suspension Page

Repairing the front wheel suspension ...................................................................................... 40-1- I - Summary of the components of the assembly carrier, anti-roll bar, track control arm ......... 40-2- Removing and installing the track control bar .......................................................................... 40-4- Pressing out and pressing in the bearing for track control arm ................................................ 40-8- Removing and installing the assembly carrier ......................................................................... 40-10- Pressing out and pressing in the rubber-metal bearing ........................................................... 40-12- II - Summary of the components of the wheel bearing, suspension strut, drive shaft, brakes .... 40-13- Repairing a wheel bearing housing .......................................................................................... 40-16- Checking the steering joint ....................................................................................................... 40-19- Removing and installing the steering joint ............................................................................... 40-20- Removing and installing a suspension strut and a wheel bearing housing .............................. 40-21- Repairing the suspension strut at the front .............................................................................. 40-25- Checking dampers ................................................................................................................... 40-28- Disposing of dampers .............................................................................................................. 40-31- Removing and installing drive shafts ....................................................................................... 40-34

Repairing a drive shaft ............................................................................................................... 40-38- Repairing a drive shaft with an outer and inner constant velocity joint .................................... 40-38- Repairing a drive shaft with an outer and inner constant velocity joint VL 3700 ...................... 40-39.1- Checking an outer constant velocity joint ................................................................................. 40-45- Checking an inner constant velocity joint ................................................................................. 40-46- Repairing a drive shaft with an inner tripod joint AAR 2900 and outer constant joint velocity ..... 40-49- Dismantling a tripod joint AAR 2900 and assembling it again .................................................. 40-51- Repairing a drive shaft with an inner tripod joint AAR 2000 and outer constant velocity joint ..... 40-56- Dismantling a tripod joint AAR 2000 and assembling it again .................................................. 40-58

42 Rear wheel suspension Page

Repairing the rear axle - drum brakes ....................................................................................... 42-1- Removing and installing the rear axle ...................................................................................... 42-1- Summary of components of the rear axle ................................................................................ 42-4- Removing and installing a rubber-metal bearing ..................................................................... 42-7- Removing and installing dampers/springs ............................................................................... 42-10- Dismantling a damper and assembling it again ....................................................................... 42-11

Repairing the rear axle - disc brakes ........................................................................................ 42-12- Removing and installing the rear axle ...................................................................................... 42-12- Summary of components of the rear axle ................................................................................ 42-15- Removing and installing a rubber-metal bearing ..................................................................... 42-18- Removing and installing dampers/springs ............................................................................... 42-21- Dismantling a damper and assembling it again ....................................................................... 42-22

Repairing the wheel bearing system ......................................................................................... 42-23- Repairing the wheel bearing system - drum brakes ................................................................. 42-23- Repairing the wheel bearing system - disc brakes .................................................................. 42-28

Service OCTAVIA

Edition 06.05S00.5103.68.20

------------ II ------------

Repairing the rear axle (vehicles with a four-wheel drive) ...................................................... 42-32- An overview of the rear axle with four-wheel drive .................................................................. 42-32- Summary of components for springs and dampers on vehicles with a four-wheel drive ......... 42-33- Removing and installing helical springs ................................................................................... 42-35- Removing and installing dampers ............................................................................................ 42-39

Summary of components of the trailing arm and suspension arm ........................................ 42-41- Pressing out and pressing in the wheel bearing ...................................................................... 42-44- Removing and installing the rubber-metal bearing for the trailing arm .................................... 42-50- Removing and installing guide joints ........................................................................................ 42-52- Removing and installing a trailing arm ..................................................................................... 42-54- Removing and installing a suspension arm ............................................................................. 42-58

A summary of components for an assembly carrier with axial drive ..................................... 42-60- Removing and installing an assembly carrier with axial drive .................................................. 42-61- Removing and installing the rubber-metal bearing for an assembly carrier ............................. 42-66- Removing and installing the rubber-metal bearing for an axial drive ....................................... 42-68

Repairing a drive shaft ............................................................................................................... 42-72- Removing and installing drive shaft ......................................................................................... 42-72- Repairing a drive shaft with constant velocity joint .................................................................. 42-75

44 Wheels/tyres/vehicle measurement Page

Vehicle measurement ................................................................................................................. 44-1- Conditions for performing checking and tests .......................................................................... 44-2- Making preparations to take measurements ............................................................................ 44-2.1- Designations of the various chassis available ......................................................................... 44-2.2- Nominal value for vehicle measurement .................................................................................. 44-2.2- Checking the lateral inclination ................................................................................................ 44-2.3- Checking the wheel camber of the front axis, averaging if necessary ..................................... 44-2.4- Checking the wheel camber of the rear axis ............................................................................ 44-2.5- Checking the wheel camber of the rear axis, averaging/adjusting if necessary ...................... 44-2.5- Checking the wheel camber of the front axis, adjusting if necessary ...................................... 44-2.6- Checking the steering angle on the left and right ..................................................................... 44-2.6- Mathematical determination of the deviation of the rear axle from the direction of travel ........ 44-2.8

Wheels and tyres ......................................................................................................................... 44-3- The disc wheel ......................................................................................................................... 44-3- The light metal wheel ............................................................................................................... 44-4

45 The Anti-Lock Braking System Page

The anti-lock braking (ABS) ITT Mark 20 IE .............................................................................. 45-1- Safety measures, basics concerning searching for faults and repair

of the ABS and ABS/EDL ITT Mark 20 IE ................................................................................ 45-1- Information concerning repair work on an ABS and ABS/EDL ITT Mark 20 IE ........................ 45-1- Required technical information ................................................................................................ 45-3

Differences in the features of the ABS ITT Mark 20 IE and the ABS/EDL ITT Mark 20 IE ..... 45-4- General comments ................................................................................................................... 45-4- The ABS ITT Mark 20 IE .......................................................................................................... 45-4- The ABS/EDL ITT Mark 20 IE .................................................................................................. 45-5- Installed position of the ABS or ABS/EDL ITT Mark 20 IE ....................................................... 45-5

Self-diagnosis .............................................................................................................................. 45-6- Function of the self-diagnostic system ..................................................................................... 45-6- Indication of faults concerning the warning lamps K47 and K14/33 ........................................ 45-7- A vehicle with ABS/EDL has no EDL function .......................................................................... 45-8

------------ III ------------

OCTAVIA Service

Edition 06.05S00.5103.68.20

Undertaking the self-diagnosis .................................................................................................. 45-9- Conditions for performing checking and tests .......................................................................... 45-9- Connecting up to the V.A.G vehicle tester 1552 and selecting a function ................................ 45-9- Querying the control unit version ............................................................................................. 45-10- An overview of the functions which can be selected ................................................................ 45-12- Interrogating the fault memory ................................................................................................. 45-12- The automatic testing sequence .............................................................................................. 45-13- The fault table .......................................................................................................................... 45-14- Deleting the fault memory ........................................................................................................ 45-21- Ending output ........................................................................................................................... 45-22- Coding the control unit ............................................................................................................. 45-22- Reading the measuring value block ......................................................................................... 45-24- Actuator diagnosis ................................................................................................................... 45-29- Initiating the basic setting ......................................................................................................... 45-36

Electrical testing of the ABS and ABS/EDL ITT Mark 20 IE ..................................................... 45-41- Conditions for performing checking and tests .......................................................................... 45-41- Multiple plug connectors with contact allocation ...................................................................... 45-42- An overview of the test steps ................................................................................................... 45-43- Testing table ............................................................................................................................. 45-44

Electrical/electronic components and installed locations of the ABS, ABS/EDL ITT Mark 20 IE ............................................................................................................. 45-51- Removing and installing the hydraulic control unit and holder ................................................. 45-52- Repairing the hydraulic control unit .......................................................................................... 45-57- Testing parts of the ABS system on the front axle/removing and installing .............................. 45-60- Testing parts of the ABS system on the rear axle/removing and installing

(drum and disc brakes - front-wheel drive ................................................................................ 45-65- Removing and installing as well as adjusting a brake light switch up to MY 1999 ................... 45-69- Removing and installing as well as adjusting a brake light switch as of MY 2000 ................... 45-69.1

A summary of components for the hydraulic control unit, brake booster/master brake cylinder for vehicles with ABS, ABS/EDL ITT Mark 20 .................................................. 45-70

Self diagnosis of the ABS/EDL for a four-wheel drive vehicle with a Haldex clutch ............ 45-71- Querying the control unit version ............................................................................................. 45-71- Fault table for ABS/EDL for a four-wheel drive vehicles with a Haldex clutch ......................... 45-72- Coding the control unit ............................................................................................................. 45-73- Testing the sender for longitudinal acceleration -G251- ........................................................... 45-74- Testing the data-bus lines ........................................................................................................ 45-75- Initiating the basic setting ......................................................................................................... 45-76- Switching off the sender for longitudinal acceleration -G251- .................................................. 45-76- Zero balancing of the sender for longitudinal acceleration -G251- .......................................... 45-77

Electrical testing of the ABS/EDL for a four-wheel drive vehicle with a Haldex clutch ........ 45-79- Test table .................................................................................................................................. 45-79

Electrical/electronic components and fitting locations (four-wheel drive) ........................... 45-81- Removing and installing the sender for longitudinal acceleration -G251- ................................ 45-82- Testing parts of the ABS system on the rear axle/removing and installing (disc brakes)

S-four-wheel drive .................................................................................................................... 45-82

The anti-lock braking system ABS/EDL/ESP ITT Mark 20 IE ................................................... 45-88- Safety measures, basics concerning searching for faults and repair ....................................... 45-88- Information concerning repair work on the ABS/EDL/ESP ITT Mark 20 IE .............................. 45-88- Required technical information ................................................................................................ 45-88

Differences in the features of the ABS ITT Mark 20 IE and the ABS/EDL/ESP ITT Mark 20 IE .................................................................................................................................... 45-89- General comments ................................................................................................................... 45-89- The ABS/EDL/ESP ITT Mark 20 IE .......................................................................................... 45-90- Fitting position of the ABS/EDL/ESP ITT Mark 20 IE ............................................................... 45-90

Self-diagnosis of the diagnosis ABS/EDL/TCS/ESP ITT Mark 20 IE ....................................... 45-91- Function of the self-diagnostic system ..................................................................................... 45-91- Indication of faults concerning the warning lamps K47, K118 and K155 ................................. 45-92- A vehicle with ABS/EDL/ESP has no EDL function .................................................................. 45-96

Service OCTAVIA

------------ IV ------------ Edition 06.05S00.5103.68.20

Undertaking the self-diagnosis .................................................................................................. 45-97- Conditions for performing checking and tests .......................................................................... 45-97- Connecting up to the V.A.G vehicle tester 1552 and selecting a function ................................ 45-97- Querying the control unit version ............................................................................................. 45-98- The automatic testing sequence .............................................................................................. 45-100- An overview of the functions which can be selected ................................................................ 45-100- Interrogating the fault memory ................................................................................................. 45-101- The fault table .......................................................................................................................... 45-102- Deleting the fault memory ........................................................................................................ 45-113- Ending output ........................................................................................................................... 45-114- Coding the control unit ............................................................................................................. 45-114- Reading the measuring value block ......................................................................................... 45-116- Initiating the basic setting ......................................................................................................... 45-124- The logging-in procedure ......................................................................................................... 45-131

Electrical testing of the ABS/EDL/ESP ITT Mark 20 IE ............................................................. 45-133- Conditions for performing checking and tests .......................................................................... 45-133- Multiple plug connectors with contact allocation ...................................................................... 45-134- Testing table ............................................................................................................................. 45-138- Test steps 1 - 20 ....................................................................................................................... 45-138- Test steps 21 - 28 ..................................................................................................................... 45-148

Electrical/electronic components and installed locations of the ABS/EDL/ESP ITT Mark 20 IE .................................................................................................................................... 45-155- Removing and installing the hydraulic control unit ABS/EDL/ESP and holder ......................... 45-158- Repairing the hydraulic control unit ABS/EDL/ESP .................................................................. 45-163- Testing parts of the ABS system on the front axle/removing and installing .............................. 45-166- Testing parts of the ABS system on the rear axle/removing and installing

(drum and disc brakes - front-wheel drive ................................................................................ 45-170- Removing and installing parts of the ESP system ................................................................... 45-170- Removing and installing as well as adjusting a brake light switch ........................................... 45-176

A summary of components for the hydraulic control unit, brake booster/master brake cylinder for vehicles with ABS/EDL/ESP ITT Mark 20 ................................................... 45-177

The anti-blocking system (ABS) MK60 ..................................................................................... 45-179- Safety measures, basics concerning searching for faults and repair of the ABS

and ABS/TCS/EDL ITT MK 60 ................................................................................................. 45-179- Information concerning repair work on an ABS and ABS/TCS/EDL ITT MK 60 ....................... 45-179- Required technical information ................................................................................................ 45-179- General guidelines ................................................................................................................... 45-179- ABS and ABS/TCS/EDL ........................................................................................................... 45-179- Installed position of the ABS or ABS/TCS/EDL ITT MK 60 ...................................................... 45-179

Self-diagnosis .............................................................................................................................. 45-180- Function of the self-diagnostic system ..................................................................................... 45-180- Indication of faults concerning the warning lamps K47 and K14/33 ........................................ 45-180

Undertaking the self-diagnosis .................................................................................................. 45-182- Conditions for performing checking and tests .......................................................................... 45-182- Connecting up to the V.A.G vehicle tester 1552 and selecting a function ................................ 45-182- An overview of the functions which can be selected ................................................................ 45-182- The fault table .......................................................................................................................... 45-183- Coding the control unit ............................................................................................................. 45-190- Table of codes for vehicles with Anti-Lock Brake System Mark 60 .......................................... 45-191- Reading the measuring value block ......................................................................................... 45-192- Actuator diagnosis ................................................................................................................... 45-194- Initiating the basic setting ......................................................................................................... 45-194

Electrical/electronic components and installed location of the Mark 60 ............................... 45-195- Removing and installing the hydraulic control unit and holder ................................................. 45-196- Repairing the hydraulic control unit .......................................................................................... 45-200- Testing parts of the ABS system on the front axle/removing and installing .............................. 45-201- Testing parts of the ABS system on the rear axle/removing and installing

(drum and disc brakes) - front-wheel drive .............................................................................. 45-203

A summary of components for the hydraulic control unit, brake booster/master brake cylinder for vehicles with ABS/EDL/TCS 20 Mark 60 .................................................... 45-204

------------ V ------------

OCTAVIA Service

Edition 06.05S00.5103.68.20

Electrical testing of the ABS/EDL/TCS Mark 60 ....................................................................... 45-205- Conditions for performing checking and tests .......................................................................... 45-205- Multiple plug connectors with contact allocation ...................................................................... 45-206- Testing table ............................................................................................................................. 45-208

The anti-lock braking system ABS/EDL/ESP MK 60 ................................................................ 45-214- Safety measures, basics concerning searching for faults and repairs ..................................... 45-214- Information concerning repair work on an ABS/EDL/ESP Mark 60 .......................................... 45-214- Required technical information ................................................................................................ 45-214

Electrical/electronic components and installed locations of the ABS/EDL/TCS/ESP Mark 60 MY02 .......................................................................................................................... 45-215

Electrical/electronic components and installed locations of the ABS/EDL/TCS/ESP Mark 60 MY02 .......................................................................................................................... 45-217.1

Differences in the features of the ABS/EDL/TCS Mark 60 and the ABS/EDL/ESP Mark 60 ..... 45-218- General comments ................................................................................................................... 45-218- Installed position of the ABS/EDL/TCS/ESP Mark 60 .............................................................. 45-218

Self-diagnosis of the diagnosis ABS/EDL/TCS/ESP Mark 60 .................................................. 45-219- The function ............................................................................................................................. 45-219- Indication of faults concerning the warning lamps K47, K14/33 and K155 .............................. 45-219

Undertaking the self-diagnosis .................................................................................................. 45-223- Conditions for performing checking and tests .......................................................................... 45-223- Connecting up to the V.A.G vehicle tester 1552 and selecting a function ................................ 45-223- Querying the control unit version ............................................................................................. 45-223- An overview of the functions which can be selected ................................................................ 45-224- The fault table .......................................................................................................................... 45-224- Coding the control unit ............................................................................................................. 45-237- Reading the measuring value block ......................................................................................... 45-238- Initiating the basic setting ......................................................................................................... 45-241- The logging-in procedure ......................................................................................................... 45-249

Electrical testing of the ABS/EDL/ESP Mark 60 ....................................................................... 45-250- Conditions for performing checking and tests .......................................................................... 45-250- Multiple plug connectors with contact allocation ...................................................................... 45-251- Testing table ............................................................................................................................. 45-254

46 Brakes/brake mechanics Page

Repairing a front wheel brake .................................................................................................... 46-1- Repairing a front wheel brake, brake calliper FS-III ................................................................. 46-1- Removing and installing brake linings or brake calliper (FS-III) ............................................... 46-3- Repairing a front wheel brake, brake calliper FN-3 .................................................................. 46-5- Removing and installing brake linings/brake calliper (FN-3) .................................................... 46-5.2- Removing and installing brake discs (FN-3) ............................................................................ 46-5.7

Repairing a rear wheel brake - front wheel drive/drum brake ................................................. 46-6- Removing and installing a rear brake ...................................................................................... 46-6- Resetting a brake ..................................................................................................................... 46-7- Repairing a rear wheel brake ................................................................................................... 46-8- Removing and installing brake linings ...................................................................................... 46-10- Adjusting the handbrake (drum brake) ..................................................................................... 46-12

Repairing a rear wheel brake - front wheel drive/disc brake .................................................. 46-13- Removing and installing a rear brake ...................................................................................... 46-13- Removing and installing brake lining ....................................................................................... 46-15- Adjusting the handbrake (disc brake) ...................................................................................... 46-17

Removing and installing the handbrake cable (front wheel drive/drum brake) .................... 46-17.2

Removing and installing the handbrake cable (front wheel drive/disc brake) ...................... 46-17.3

Summary of components: the handbrake cable ...................................................................... 46-18

Summary of components: foot-operated system, brake pedal .............................................. 46-19- Disconnecting the brake pedal from the brake booster and clipping them together ................ 46-20- Removing and installing the brake pedal ................................................................................. 46-22

Service OCTAVIA

------------ VI ------------ Edition 06.05S00.5103.68.20

Repairing a rear wheel brake - four-wheel drive/disc brake ................................................... 46-24- Removing and installing a rear brake ...................................................................................... 46-24- Removing and installing brake linings ...................................................................................... 46-26- Adjusting the handbrake .......................................................................................................... 46-29

Removing and installing the handbrake cable (four-wheel drive/disc brake) ....................... 46-31

47 Brakes/brake hydraulics Page

A summary of components for the brake booster/master brake cylinder for vehicles without ABS or ABS/EDL Mark 20 ............................................................................................. 47-1- Removing and installing the master brake cylinder ................................................................. 47-2- Checking the brake booster ..................................................................................................... 47-4- Removing and installing the brake booster .............................................................................. 47-4.1- Removing and installing the vacuum pump for the brake booster ........................................... 47-7

Repairing a front brake calliper, brake calliper FS-III .............................................................. 47-8- A summary of components of the brake calliper FS-III ............................................................ 47-8- Removing and installing pistons for the front brake calliper ..................................................... 47-9

Repairing a front brake calliper, brake calliper FS-3 ............................................................... 47-10.1- A summary of components of the brake calliper FS-3 ............................................................. 47-10.1- Removing and installing pistons for the front brake calliper ..................................................... 47-10.2

Repairing a rear brake calliper ................................................................................................... 47-11- A summary of components of the brake calliper ...................................................................... 47-11- Removing and installing the piston for the front brake calliper ................................................ 47-12

A summary of components of the brake force regulator ........................................................ 47-15

Checking and adjusting the brake force regulator .................................................................. 47-16- Setting values for the load-oriented brake force regulator ....................................................... 47-17

Ventilating the brake system on vehicles with and without ABS or ABS/EDL Mark 20 and Mark 60 ................................................................................................................................. 47-18- Ventilating the brake system using a brake draining and ventilation device such

as ROMESS S15 for vehicles with Mark 20 ............................................................................. 47-20- Ventilating the brake system without the use of a brake draining and ventilation device ........ 47-21- Changing the brake fluid .......................................................................................................... 47-22- Ventilating the brake system using a brake draining and ventilation device such a

s ROMESS S15 for vehicles with Mark 60 ............................................................................... 47-23

Tightness test of the master brake cylinder ............................................................................. 47-24

A summary of components: brake booster/master brake cylinder for vehicles with ABS/EDL/ESP Mark 20 ........................................................................................................ 47-26- Removing and installing sender -1- for brake pressure -G201- and sender -2- for

brake pressure -G214- ............................................................................................................. 47-28- Removing and installing the master brake cylinder ................................................................. 47-30- Checking the brake booster ..................................................................................................... 47-32- Removing and installing the brake booster .............................................................................. 47-32- Removing and installing the vacuum pump for the brake booster ........................................... 47-35

A summary of components: brake booster/master brake cylinder for vehicles with ABS/EDL/TCS/ESP Mark 60 ................................................................................................ 47-36- Removing and installing sender -1- for brake pressure -G201- ............................................... 47-37- Removing and installing the master brake cylinder ................................................................. 47-37- Checking the brake booster ..................................................................................................... 47-37- Removing and installing the brake booster .............................................................................. 47-37- Removing and installing vacuum pump for the brake -V192- .................................................. 47-38- Checking vacuum pump for the brake -V192- ......................................................................... 47-39

48 The steering system Page

Steering column and steering wheel with airbag ..................................................................... 48-1- Checking the steering column for damage .............................................................................. 48-1- Removing and installing the steering column .......................................................................... 48-2- Removing and installing the ignition lock housing with the steering column mounted in place ... 48-8.3

------------ VII ------------

OCTAVIA Service

Edition 06.05S00.5103.68.20

A summary of components: the power-assisted steering gearing system ........................... 48-9- Removing and installing the expansion bottle for hydraulic oil ................................................ 48-11- Removing and installing the power-assisted steering gearing system .................................... 48-12- Repairing the power-assisted steering gearing system (ZF) ................................................... 48-19- Altered track rod ends .............................................................................................................. 48-23.1- Altered track rods ..................................................................................................................... 48-23.2- Disposing of a power-assisted steering gearing system .......................................................... 48-24- Adjusting a power-assisted steering gearing system (ZF) ....................................................... 48-25- Checking the hydraulic fluid level on a power-assisted steering system and topping it

up where necessary ................................................................................................................. 48-26- Emptying a power-assisted steering system, filling and ventilating ......................................... 48-28- Checking a power-assisted steering system for leaks ............................................................. 48-30- Noises on a power-assisted steering system ........................................................................... 48-31

A summary of components: the vane pump ............................................................................ 48-33- A summary of components for vane pumps which are mounted above and below ................. 48-33- Pressure switch for the power-assisted steering system ......................................................... 48-34- Checking the delivery pressure of the vane pump ................................................................... 48-35

Removing and installing the vane pump .................................................................................. 48-37- Vehicles with the vane pump mounted above .......................................................................... 48-37.1- Vehicles with the vane pump mounted below .......................................................................... 48-41- Disposing of a vane pump ....................................................................................................... 48-45

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OCTAVIA00 Technical Data

Edition 06.05S00.5103.68.20

Continuation of table Nominal values of front axle of page 00-1

Spring strut axle (Front and 4-Wheel Drive)

Standard suspension7) Sport suspension Rough road suspension

Camber3) -30 30 -33 30 -16 30

-0 25 304)6) - -

-0 28 305) - -

Max. difference between left and right side

30 30

Caster angle1) 7 40 308) 7 50 308) 7 15 308)

7 40 +30, -609) 7 50 +30, -609) 7 15 +30, -609)

8 23 304) - -

8 305)6) - -

Max. difference of caster angle between left and right side

30 30

------------ 00-2 ------------

Comment:Technical data apply for the unladen weight of the vehicle ready for driving (full fuel tank and water reservoir for the windscreen wiper washer system, spare wheels, tool kit, jack and without driver).

1) Not adjustable, depending on design

3) The camber can be changed marginally, by moving the assembly carrier. Pay attention to: Always replace the screws and washers of the assembly carrier! After carrying out corrections of steering geometry, inspect position of steering wheel and alter to correct position,

if necessary.

4) Only Service Mobil (Octavia 1.9 l/66 kW SLX, Octavia 1.8 l/92 kW SLX)

5) Only Service Mobil (Octavia Estate 1.9 l/81 kW SLX)

6) Only Service Mobil (Octavia 1.9 l/66 kW GLX

7) Not valid for Octavia 4 x 4

8) up to MY 2000

9) as of MY 2001

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OCTAVIA Technical Data 00

Edition 06.05S00.5103.68.20

------------ 00-5 ------------

Steering

Model All

Steering type Rack and pinion type steering system

Steering gear Power-steering gear

Steering-wheel turns from stop to stop 3.04

Steering-wheel diameter (mm) 370

Total ratio of steering 15.60

Lubricant for gear racks Steering gear-flow greaseTL 733

N 052 733 00Part No.: AOF 063 000 04(e.g. DEA ORNA F6 EPO)

Filling weight (g) 23...27

Maximum clearance between pressure plate and cover (mm)

0.05...0.1

Authorised axial force for the displacement of the gear rack (N)

250

Rotating force of the track rods from rest position (N) 1...3.5

Hydraulic oil designation Hydraulic oilTL 52 146

N 052 146 00Part No.: G 002 000(e.g. PENTOSIN CHF 11S)

Hydraulic oil amount in the system (l) 0.7...0.9 l

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This report was created automatically with help of the Adobe Acrobat Distiller addition "Distiller Secrets v1.0.5" from IMPRESSED GmbH.You can download this startup file for Distiller versions 4.0.5 and 5.0.x for free from http://www.impressed.de.

GENERAL ----------------------------------------File Options: Compatibility: PDF 1.3 Optimize For Fast Web View: Yes Embed Thumbnails: Yes Auto-Rotate Pages: Individually Distill From Page: 1 Distill To Page: All Pages Binding: Left Resolution: [ 400 400 ] dpi Paper Size: [ 595 842 ] Point

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IMPRESSED GmbHBahrenfelder Chaussee 4922761 Hamburg, GermanyTel. +49 40 897189-0Fax +49 40 897189-71Email: [email protected]: www.impressed.de

/AutoFilterColorImages false /sRGBProfile (sRGB IEC61966-2.1) /ColorImageDepth 8 /PreserveOverprintSettings true /AutoRotatePages /PageByPage /UCRandBGInfo /Preserve /EmbedAllFonts true /CompatibilityLevel 1.3 /StartPage 1 /AntiAliasColorImages false /CreateJobTicket true /ConvertImagesToIndexed true /ColorImageDownsampleType /Bicubic /ColorImageDownsampleThreshold 1.5 /MonoImageDownsampleType /Bicubic /DetectBlends true /GrayImageDownsampleType /Bicubic /PreserveEPSInfo true /GrayACSImageDict > /ColorACSImageDict > /PreserveCopyPage true /EncodeMonoImages true /ColorConversionStrategy /LeaveColorUnchanged /PreserveOPIComments true /AntiAliasGrayImages false /GrayImageDepth 8 /ColorImageResolution 300 /EndPage -1 /AutoPositionEPSFiles true /MonoImageDepth -1 /TransferFunctionInfo /Preserve /EncodeGrayImages true /DownsampleGrayImages false /DownsampleMonoImages false /DownsampleColorImages false /MonoImageDownsampleThreshold 1.5 /MonoImageDict > /Binding /Left /CalCMYKProfile (U.S. Web Coated (SWOP) v2) /MonoImageResolution 300 /AutoFilterGrayImages false /AlwaysEmbed [ ] /ImageMemory 524288 /SubsetFonts false /DefaultRenderingIntent /Default /OPM 1 /MonoImageFilter /CCITTFaxEncode /GrayImageResolution 300 /ColorImageFilter /FlateEncode /PreserveHalftoneInfo true /ColorImageDict > /ASCII85EncodePages false /LockDistillerParams false>> setdistillerparams> setpagedevice

OCTAVIA Technical Data 00

Edition 06.05S00.5103.68.20

Engine l/kW 1.9/66 TDI 1.9/81 TDI 1.8/92; 2.0/85 (82) 1.8/110

M = Manual gearboxA = Automatic gearbox

M A M - M A M A

Master brake cylinder - mm 23.81

Brake booster - Inch Left-hand drive with and without ABS: 10Right-hand drive with and without ABS: 7/8 - Tandem

Front brake disc

Front brake caliper FN-III3)5) FN-34)

Front brake caliper, piston - mm 54.0 54.0

Front brake disc - mm 280.0 288.0

Brake disc, thickness mm 22.0 25.0

Brake disc, minimum thickness mm 19.0 23.0

Pad thickness with supporting plate mm 19.5 19.5

Minimum thickness without sup-porting plate

mm 2.0 2.0

Rear disc brake

Rear brake caliper, piston - mm 38.08)

41.09)

Rear brake disc - mm 232.06)

239.07)232.0239.07)

Brake disc, thickness mm 9.0

Brake disc, minimum thickness mm 7.0

Pad thickness with supporting plate mm 17.0


mm 2.0

Drum brake

Brake drum - mm 230.0

Brake drum - maximum diameter mm 231.0

Wheel brake cylinder1) - mm 20.64

Wheel brake cylinder2) - mm 20.64 20.64

Pad thickness, width mm 32.0

Pad thickness without supporting plate

mm 5.5


mm 2.5

1) Vehicles without ABS

2) Vehicles with ABS

3) Not valid for Taxi vehicles (identification F4E)

4) For Taxi vehicles (F4E) also 1.9/66; 2.0/85; 1.9/81

5) For Taxi vehicles (F4E) also 1.4/44; 1.4/55; 1.6/55; 1.6/74; 1.6/75; 1.9/50

6) Vehicles with ESP

7) Four-wheel drive vehicles

8) up to 07.98

9) as of 08.98

------------ 00-7 ------------

OCTAVIA00 Technical Data

Edition 06.05S00.5103.68.20

------------ 00-8 ------------

Brake fluid

Classification Brake fluid N 052 766 US standard FMVSS 571. 116 DOT4)

Part No.: B 000 700 A.. (A1......M8 - Package size)

Contents of brake fluid l 0.49 Vehicles with rear drum brakes, without ABS0.53 Vehicles with rear drum brakes, with ABS0.57 Vehicles with rear disc brakes, with ABS

Brake fluid change - every 2 years

Wheels, Tyres

Rims:

Bolt-hole circle diameter: 100 mm

Center hole diameter: 57 mm

5-hole fixing

Engine Tyre size1) Light alloy rim Steel rim Offset (mm)

Snow chainsPermitted

yes no

1.4 l/44 kW 175/80 R14 88 T, H - 6J x 14 H2 38 X -

1.4 l/55 kW 195/65 R15 91 T, H, V 6J x 15 H2 6J x 15 H2 X -

1.6 l/55 kW 205/60 R15 91 H 61/2J x 15 H2 - 43 - X

1.9 l/50 kW 205/55 R16 91 H 61/2J x 16 H2 - 42 - X

205/55 R16 91 W 51/2J x 16 H2 - 36 X -

1.6 l/74 kW 175/80 R14 88 H - 6J x 14 H2 38 X -

1.6 l/75 kW 195/65 R15 91 H, V 6J x 15 H2 6J x 15 H2 X -

205/60 R15 91 H 61/2J x 15 H2 - 43 - X

205/55 R16 91 H 61/2J x 16 H2 - 42 - X

205/55 R16 91 W 51/2J x 16 H2 - 36 X -

2.0 l/85 kW 195/65 R15 91 H, V 6J x 15 H2 6J x 15 H2 38 X -

205/60 R15 91 H 61/2J x 15 H2 43 - X

205/55 R16 91 H 61/2J x 16 H2 42 - X

205/55 R16 91 W 51/2J x 16 H2 36 X -

Continued table page 00-9

1) Tyre inflation pressure Inspection and Maintenance;

as well as sticker on vehicle

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END OF REPORT ----------------------------------------



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Front Suspension 40

Edition 10.98

Servicing front suspension

I - Removing and installing subframe, anti-rollbar, track control arm page 40-2

II - Removing and installing wheel mounting,suspension strut, drive shaft, brake page 40-13

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40 Front Suspension

Edition 10.98

Removing and installing track con-trol arm

Special tools, testers and aids required

Removing tool MP 6-425

Supporting device MP 9-200

Torque wrench 75 ... 400 Nm,e.g. V.A.G 1576

Torquing angle wrench, e.g. V.A.G 1756

Removing

- Take off the wheel trim; pull off cap on light-alloy wheels (hook included in tool kit).

- Jack up vehicle until no weight is pressingon the front suspension.

- Slacken twelve-point nut.

- Raise vehicle and take off wheel.

- Unscrew twelve-point nut.

- Remove noise insulation panel. Engine, Mechanical Components; Repair

Group 10; Removing and installing engine

Only for models with automatic gearbox:

- Insert supporting device MP 9-200 and takeup weight of engine/gearbox in this position.

All models:

Note:Mark installation position of the bolts -1- other-wise the axle geometry must be checked.

- Unscrew bolts -1-.

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END OF REPORT ----------------------------------------



40 Front Suspension

Edition 12.98

Removing and inserting bush fortrack control arm


Thrust plate MP 3-406


Pipe section MP 3-414

Pipe section MP 3-429

Thrust washer MP 3-456

Assembly device MP 5-402

Assembly device MP 6-401

Plunger MP 6-405

Base MP 6-407

Extraction tube MP 6-408

Workshop pressing tool, e.g. V.A.G 1290 A

Acid-free lubricant, e.g. G 294 421

Pressing out front bush for track control arm

Inserting front bush for track control arm

- Insert bush into pipe section MP 3-414.

Note:Use acid-free lubricant, e.g. G 294 421, for in-serting the bush. On no account use grease orsoapsuds.

Front Suspension 40

Edition 10.98

Installation position for rear bush in trackcontrol arm

One of the stamped arrows points towards therecess in the track control arm; kidney-shapedrecess (arrow A) in bush points toward centreof vehicle.

Removing and inserting rear bush for trackcontrol arm

Pay attention to installation position when insert-ing Fig. V40-1010.

40 Front Suspension

Edition 10.98

Removing and installing subframe


Removal tool MP 6-425

Gearbox jack with attachment,e.g. V.A.G 1383 A with V.A.G 1359/2

Removing

- Take off the wheel trims of the front wheels;remove caps on light-alloy wheels (hook in-cluded in tool kit).

- Jack up vehicle sufficiently so that there isno load pressing on the front suspension.

- Slacken twelve-point nut on left and right.

- Raise vehicle and take off wheels.

- Unscrew twelve-point nut on left and right.

- Remove noise insulation panel. Engine, Mechanical Components; Repair

Group 10; Removing and installing engine

Note:Mark installation position of bolts -1- otherwisethe axle geometry must be checked.

- Unscrew bolts -1-.

- Press out drive shaft on left and right. Posi-tion tool as shown in illustration for this step.

Note:Ensure adequate clearance when pressing outthe drive shafts.

- Separate track control arm on left and rightfrom steering joint.

- Swivel wheel bearing housing and steeringjoint out and support.

Front Suspension 40

Edition 10.98

- Unscrew bolts -1- and -2- and take off pen-dulum support.

- Unscrew bolts for steering gear -5-.

- Unscrew nut -7- for coupling rod of anti-rollbar.

- Unscrew bolts -6- for exhaust system(only TDI).

- Position gearbox jack with attachment, e.g.V.A.G 1383 A with V.A.G 1359/2, belowsubframe.

- Unscrew bolts -3- and -4- for subframe.

- Lower subframe with gearbox jack.Note:Ensure that the steering gear detaches from thesubframe.

- Support steering gear; take up weight withtensioning strap if necessary.

Installing

Before fitting on the bolts for the subframe, po-sition steering gear on subframe and then in-sert bolts for steering gear.

The threaded sleeve -1- should be locatedin the hole of the subframe.

The remaining installation is carried out in thereverse order.

Tightening torques page 40-2.

After installing, carry out a road test in order tocheck the position of the steering wheel.

If the steering wheel is not properly centred, it isthen necessary to check the axle alignment.

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OCTAVIA Front Wheel Suspension 40

Edition 06.05S00.5103.68.20

------------ 40-15 ------------

9 - Brake disc (FS-III) without marking for axial run-out with a fixing hole for the wheel hub assignment electronic catalogue of

original parts

10 - Wheel bolt, 120 Nm

11 - Twelve-point nut, self-locking loosen and tighten page 40-6 replace after each disassembly

12 - Screw, 4 Nm

13 - Brake pads (FS-III) removing and installing

page 46-3

14 - Brake caliper (FS-III)For vehicles with engine up to 92 kW. do not release brake hose when work-

ing on the front wheel suspension tie up with wire or anything similar repairing page 47-8

15 - Guide bolts (FS-III), 28 Nm removing and installing from page

46-3

16 - Cap (FS-III)

17 - Brake disc (FN-3) with marking for axial run-out with 5 fixing holes for the wheel hub removing and installing from page

46-5.7 assignment electronic catalogue of

original parts

18 - Wheel hub with pulse rotor for speed sensor with marking for minimum axial run-

out only on vehicles with ABS pressing out page 40-16 and futher pressing in page 40-16 and further removing inner ring of bearing page

40-16 and further inspecting lateral run-out of pulse ro-

tor page 45-61 assignment electronic catalogue of

original parts

19 - Brake pads (FN-3) removing and installing

page 46-5.2

20 - Retaining spring (FN-3)

21 - Brake carrier (FN-3)

22 - Brake caliper (FN-3)For vehicles with engine as of 96 kW do not release brake hose when work-

ing on the front wheel suspension tie up with wire or anything similar removing and installing brake pads

Repair Group 46 repairing Repair Group 47

23 - Guide bolts (FN-3), 28 Nm removing and installing

page 46-5.2

24 - Cap (FN-3)

25 - Bolt with safety collar (FN-3), 125 Nm clean ribbing on underside

26 - Wheel bearing housingFor vehicles with engine as of 96 kW removing and installing

page 40-21 repairing from page 40-16 before pressing in wheel bearing coat

evenly the entire wheel bearing seat in the wheel bearing housing with G 052 723 A2

27 - Cover plate

28 - Self-locking nut, 45 Nm replace after each disassembly

29 - Steering joint inspecting page 40-19 inspecting rubber bellows for damage,

if necessary replace steering joint removing and installing

page 40-20

30 - Wheel bearing housingFor vehicles with engine up to 92 kW removing and installing

page 40-21 repairing from page 40-16 before pressing in wheel bearing coat

evenly the entire wheel bearing seat in the wheel bearing housing with G 052 723 A2

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40 Front Wheel Suspension

Edition 04.03

Repairing wheel bearing housing




Thrust plunger MP 3-408

Tube section MP 3-4012

Tube section MP 3-450


Ring wrench WAF 46 MP 6-413

Assembly device MP 6-414/1

Washer MP 6-415

Washer MP 6-416


Tube MP 6-419

Pressure pipe MP 6-420

Extractor MP 6-425

Socket wrench insert WAF 21 MP 6-427

Spreader 3424

Extractor Kukko V 176

Workshop press, e.g. V.A.G 1290 A

Torque wrench, e.g. V.A.G 1756

Cross member Kukko 18-0

Grease G 052 723 A2 (Molykote)The repair of the wheel bearing housing bypressing out and in the wheel hub and the wheelbearing is only possible after removing the sus-pension strut and wheel bearing housing.

- Removing and installing suspension strutand wheel bearing housing page 40-21.

Front Suspension 40

Edition 03.97

Pressing wheel hub out of wheel bearing

Removing and installing circlip

- Use commercially available circlip pliers toremove and replace circlip.

Notes: Replace When inserting, ensure the circlip is correctly

located.

Pressing wheel bearing out of wheel bearinghousing

40 Front Wheel Suspension

Edition 04.03

Pull the inner ring of the bearing off the wheelhub

- Insert washer MP 6-416 as shown.

- Screw cross member Kukko 18-0 into washerMP 6-416.

- Install pressure plate MP 3-467 onto wheelhub and pull off inner ring of bearing by turn-ing the threaded spindle.

Press wheel bearing into wheel bearing hous-ing

A - wheel bearing

- Before pressing in wheel bearing coat evenlythe entire wheel bearing seat in the wheelbearing housing with G 052 723 A2.

Note:After pressing in the wheel hub, the circlip mustbe inserted page 40-17.

Press wheel hub into wheel bearing

Note: When pressing in the wheel hub, make sure

the washer MP 6-415 is supported at the in-ner ring of the bearing.

Observe assignment of wheel hub with wheelbearing housing and wheel hub for vehicleswith engine as of 110 kW (Brake FN-3)

Spare Part catalogue. Wheel hubs with a 3 mm wide ink jet mark

for marking of minimum axial run-out can alsobe combined with brake discs without mark-ing of maximum axial run-out.The reduction of the entire axial run-out forBrake FN-3 is then not effective.

Front Suspension 40

Edition 09.96

Inspecting steering jointInspecting axial play

- Pull steering link firmly down and push upagain.

Inspecting radial play

- Push wheel firmly in and out at the bottom.

Notes: There must not be any perceptible or visible

play present when conducting bothinspections.

Observe steering joint when carrying out theinspections.

Allow for any wheel bearing play which ispresent or play in the top suspension strutbush.

Inspect rubber boot for damage; replacesteering joint if necessary.

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OCTAVIA40 Front Wheel Suspension

Edition 06.05S00.5103.68.20

------------ 40-22 ------------

- Use puller Matra V176 (commercial) to press track rod off the steering arm

- Unplug connector -1- ABS speed sensor from the mountings.

- Disconnect the ABS speed sensor from the mountings -arrow-.

- Remove caps -2- and unscrew brake cal-liper. Secure the brake caliper with wire to the body.

- Remove the brake disc (brake disc is fixed with one screws to the wheel hub).

- If necessary remove the coupling rod from the suspension rod.

- Unscrew the suspension strut on the body using the socket wrench insert -MP 6-427

- Remove suspension strut with wheel-bear-ing housing.

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Documents

Skoda Octavia 1 service manual - Running Gear - 51035020